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OPERATION MANUAL
4BY2
6BY2
P/N: 0ABY0-G00200
MARINE
ENGINES

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Summary of Contents for Yanmar 4BY2

  • Page 1 OPERATION MANUAL 4BY2 6BY2 P/N: 0ABY0-G00200 MARINE ENGINES...
  • Page 2 / or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Yanmar and registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries.

  • Page 3: Table Of Contents

    Yanmar BY-Series Features and Applications......9 New Engine Break In..........10 Component Identification..........11 Left Side (as viewed from flywheel) - 4BY2 ....11 Right Side (as viewed from flywheel) - 4BY2 ....11 Top View - 4BY2 ........... 12 Left Side - 6BY2 ............ 12 Right Side - 6BY2 ..........
  • Page 4 The Importance of Daily Checks ....... 39 Keep a Log of Engine Hours and Daily Checks..... 39 Yanmar Replacement Parts ........39 Tools Required ............. 39 Ask Your Authorized Yanmar Marine Dealer or Distributor For Help..........39 Required EPA Maintenance ........39 EPA Requirements............40 Conditions to Ensure Compliance with EPA Emission Standards ............
  • Page 5 Prepare Engine for Long-Term Storage......69 Draining the Seawater Cooling System....... 70 Specifications..............71 Engine Specifications............71 EPA Warranty USA Only............75 Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only..............75 Your Warranty Rights and Obligations: ....... 75 Warranty Period: ........... 76 Warranty Coverage: ..........76 Exclusions: ............
  • Page 6 TABLE OF CONTENTS This Page Intentionally Left Blank BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 7: Introduction

    BSO II, SAV, EPA II, IMO and RCD. to the manual provided by the manufacturer of these components. To help you enjoy your Yanmar BY2 engine • Refer to the Yanmar Limited Warranty for many years to come, please follow these...

  • Page 8: Record Of Ownership

    INTRODUCTION RECORD OF OWNERSHIP Take a few moments to record the information you need when you contact Yanmar for service, parts or literature. Engine Model: Engine Serial No.: Date Purchased: Dealer: Dealer Phone: BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 9: Safety

    SAFETY Yanmar considers safety of great DANGER importance and recommends that anyone that comes into close contact with its Indicates an hazardous situation which, if products, such as those that install, operate, not avoided, will result in death or serious maintain or service Yanmar products, injury.

  • Page 10: Safety Precautions

    • Safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar Marine dealer or distributor for additional training. BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 11 Store any equipment in a designated area away from moving parts. NEVER use the engine compartment for storage. BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 12 NEVER check for a fuel leak with your loosening or tightening machine parts. hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar Flying Object Hazard Marine dealer or distributor repair the ALWAYS wear eye protection when damage.
  • Page 13 Immediately throttle back to approximately If a Yanmar Marine engine is installed at an 2/3 throttle or to a setting where the engine angle that exceeds the specifications stated performs normally.

  • Page 14: Safety Decals

    ( 8 ) 0006620 Figure 1 1 – 120650-07030 6 – 120650-07080 2 – 120650-07040 7 – 120650-07090 3 – 120650-07050 8 – 120650-07100 4 – 120650-07060 9 – 120650-07121 5 – 120650-07070 BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 15: Product Overview

    As new engine all require specialized knowledge boats are used, owners add additional and engineering skills. See Yanmar's local equipment and completely fill the fuel and subsidiary in your region or your authorized water tanks adding to the overall Yanmar marine dealer or distributor.

  • Page 16: New Engine Break In

    Neutral. • During the break-in period, carefully observe the engine oil pressure and engine temperature. • During the break-in period, check the engine oil and coolant levels frequently. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 17: Component Identification

    COMPONENT IDENTIFICATION Right Side (as viewed from Figure 1, Figure 2 and Figure 3 illustrate a flywheel) - 4BY2 typical version of a 4BY2 engine. Your engine may have different equipment from that illustrated. Left Side (as viewed from flywheel) - 4BY2...

  • Page 18: Top View - 4By2

    PRODUCT OVERVIEW Top View - 4BY2 Figure 4, Figure 5 and Figure 6 illustrate a typical version of a 6BY2 engine. Your engine may have different equipment from that illustrated. Left Side - 6BY2 0006560 Figure 3 1 – Fuel Fine Filter...

  • Page 19: Right Side - 6By2

    7 – Seawater Drain Cock 8 – Hydraulic Oil Cooler 7 – Air Filter 9 – Coolant Drain Plug Note: Yanmar supplies a water-separating pre-filter for mounting by the installer. The engine is equipped with an on-engine fine filter (Figure 6, (1)).

  • Page 20: Location Of Nameplates

    Gear Model Continuous power kW Speed of prop shaft Fuel stop power kW ENG.No. The typical location of the engine name plate is shown for Yanmar 4BY2 Series marine engines (Figure 7) and 6BY2 engines (Figure 8). 4BY2 Model Gear Model...
  • Page 21 STRIPS TO THE RESPECTIVE BLANK DRIVE ON THIS DECAL. 4 B Y 1 0 8 5 0 7 5 1 1 0 0 7 8 2 4 9 5 1 0006567 Figure 9 BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 22: Function Of Major Components

    The air filter removes dirt from the intake combustion air reducing engine wear. Nameplates Nameplates are provided on the engine and the marine gear and have the model, serial number and other data. BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 23 The electrical panel power leads must be connected directly to the battery, and must have a breaker installed in the B+ (red) lead. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 24: Fuses And Relays

    Helm Display 14–Connector X21/1 - Engine Wiring Harness 15–Connector X22/1 - Fuel Injector Wiring Harness NEVER connect any additional devices to F2. F6 may be used however, it is not switched. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 25: Engine Cover

    PRODUCT OVERVIEW ENGINE COVER 0006552 Figure 11 To remove the cover from the engine, remove all bolts, then lift cover from engine. BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 26 PRODUCT OVERVIEW This Page Intentionally Left Blank BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 27: Before You Operate

    BEFORE YOU OPERATE This section of the Operation Manual describes the diesel fuel, engine oil, and engine coolant specifications and how to replenish them. It also describes the daily engine checkout. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 28: Diesel Fuel

    • Bio-diesel may have adverse effects on Bio-Diesel Fuels some elastomers (seal materials) and may Yanmar approves the use of bio-diesel fuels result in fuel leakage and dilution of the that do not exceed a blend of 5% non- engine lubricating oil.
  • Page 29 • Fuel additives are not recommended. Some fuel additives may cause poor Note: Yanmar supplies a water separating engine performance. See your authorized pre-filter for mounting by the installer. The Yanmar marine dealer or distributor for engine is also equipped with an on-engine more information.

  • Page 30: Filling The Fuel Tank

    1 and 2 until the engine starts and runs. NOTICE: NEVER use an engine starting aid such as ether. Engine damage will result. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 31: Engine Oil

    3. Select the oil viscosity based on the ambient temperature where the engine is being operated. See the SAE Service Grade Viscosity Chart. 4. Yanmar does not recommend the use of engine oil “additives.” BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 32: Acceptable Engine Oil

    Jet Top Level ConocoPhillips GmbH Labo RC Fuchs Labo Auto S.A. Liqui Moly Longtime High Tech Liqui Moly Megol Motorenöl New Generation Meguin GmbH Mobil 1 ExxonMobil Mobil 1 Turbo Diesel ExxonMobil BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 33 Veedol International Veedol Syntron Veedol International Veritas Syntolube Ölwerke Julius Schindler GmbH Wako’s Super Synthe Wako Chemical Co.Ltd Wintershall VIVA 1 Longlife SRS Schmierstoff Vertrieb GmbH Yacco VX 1600 Yacco S.A.S. BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 34 Repsol Elite Evolution Repsol YPF Shell Helix Ultra AP Shell International Petroleum Company Titan GT1 Fuchs Petrolub AG Wintershall VIVA 1 topsynth alpha LS SRS Schmierstoff Vertrieb GmbH York 848 Ginouves SAS BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 35: Checking Engine Oil

    Checking Engine Oil Adding Engine Oil 0006565 Figure 5 0006568 Note: 4BY2 series shown. 6BY2 is similar. Figure 3 Note: 4BY2 series shown. 6BY2 is similar. 1. Remove the oil filler port cap 1. NOTICE: Prevent dirt and debris from (Figure 5, (2)) and pour engine oil into contaminating engine oil.

  • Page 36: Marine Gear Or Stern Drive Oil

    2. Power steering fluid level must be between the upper (Figure 6, (1)) and lower (Figure 6, (2)) level marks. ( 1 ) ( 2 ) 0004042 Figure 6 3. Add fluid if necessary. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 37: Engine Coolant

    Havoline AFC (BD04) Chevron Texaco/Arteco Mobil Frostschutz 600 ExxonMobil OMV Kühlerfrostschutz OMV AG Total Thermofreeze Plus Total Note: Yanmar recommends using genuine Yanmar antifreeze / coolant. Contact your authorized Yanmar dealer or distributor. BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 38 Never fill to the full line. 6. After filling an empty cooling system, test-run the engine for about five minutes and check the engine coolant level at the recovery tank again. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 39: Engine Operation

    NEUTRAL position any time the engine is at idle. To prevent accidental equipment movement, NEVER start the engine in gear. Sever Hazard Keep children and pets away while the engine is operating. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 40: Starting The Engine

    Note: Once the engine has started, the ECU • Contact your authorized Yanmar marine will raise the engine speed to 1080 rpm to engine dealer or distributor if the engine...

  • Page 41: Starting At Low Temperatures

    NOTICE: Be sure to close the seacock. Neglecting to close the seacock could allow water to leak into the boat and may cause it to sink. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 42: Checking The Engine After Operation

    See Engine Coolant on page 31. • If there is a risk of freezing, drain the seawater system. See Draining the Seawater Cooling System on page 70. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 43: Periodic Maintenance

    All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisioning. BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 44 Any alterations to this engine may void its warranty. Be sure to Avoid personal injury or equipment damage. use Yanmar genuine replacement parts. ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors.

  • Page 45: Precautions

    Yanmar Replacement Parts Performing Periodic Yanmar recommends that you use genuine Maintenance Yanmar parts when replacement parts are WARNING! NEVER block windows, needed. Genuine replacement parts help vents, or other means of ventilation if ensure long engine life.

  • Page 46: Epa Requirements

    The warranty period is determined by the age of the engine or the number of • Ambient temperature: -16° to +40°C hours of operation. See Yanmar Co., Ltd. (3° to 104°F) Limited Emission Control System Warranty • Relative humidity: 80% or lower - USA Only on page 75.

  • Page 47: Standard Torque Values

    Always install new hose clamps. Size Specification 5mm Hex Head 1.0 - 1.5 N·m (8.9 - 13 in.-lb) 6mm Hex Head 2.5 - 3.5 N·m (22 - 31 in.-lb) BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 48: Periodic Maintenance Schedule

    See engine application, loads, diesel fuel and your authorized Yanmar marine dealer engine oil used and are hard to establish or distributor for assistance when definitively. The following should be treated checking items marked with a ●.
  • Page 49 PERIODIC MAINTENANCE ○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor System Item Periodic Maintenance Interval Daily Every Every Every Every Every See Daily 1000 2000 Checks hours or hours hours hours hours on page...
  • Page 50 PERIODIC MAINTENANCE ○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor System Item Periodic Maintenance Interval Daily Every Every Every Every Every See Daily 1000 2000 Checks hours or hours hours hours hours on page...
  • Page 51 PERIODIC MAINTENANCE ○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor System Item Periodic Maintenance Interval Daily Every Every Every Every Every See Daily 1000 2000 Checks hours or hours hours hours hours on page...

  • Page 52: Inspection And Maintenance Of Epa Emission-Related Parts

    Inspection and Maintenance of EPA Emission-Related Parts Before heading out for the day, make sure Parts Interval the Yanmar engine is in good operating Check fuel injection nozzle 1500 hours condition. CAUTION! It is important to (cleaning) perform daily checks as listed in this Check fuel injection nozzle Operation Manual.Periodic...

  • Page 53: Checking Diesel Fuel, Engine Oil And Engine Coolant Levels

    Always store engine oil and coolant in reserve (for at least one refill) on board, to be ready for emergencies. Checking Power Steering Fluid See Checking Power Steering Fluid Level on page 30. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 54: Periodic Maintenance Procedures

    ALWAYS wear eye protection. 1. Turn engine OFF. 2. Remove engine cover. 0003652 Figure 2 BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 55: Every 50 Hours Of Operation

    Add oil wear. If necessary, consult your authorized if the level is too low. Yanmar dealer or distributor for repair. Checking Shift Cable Adjustment Checking the Battery Electrolyte See your authorized Yanmar dealer or Level (Serviceable Batteries Only) distributor.

  • Page 56: Every 250 Hours Of Operation

    • Changing the Power Steering Fluid • Checking the Shift Cable Adjustment • Adjusting the Propeller Shaft Alignment • Checking the Hydraulic Oil Cooler • Checking or Replacing Rubber Hoses • Checking Flexible Engine Mounts BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 57 6. Hand-tighten cartridge to filter. 4. Dispose of waste properly. 7. Connect battery negative (-) cable. 8. Bleed the fuel system and check for leaks. See Bleeding the Fuel System on page 24. BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 58 Replacing Fuel Filter / Water 7. Clean the filter bowl. Inspect the water Separator Element sensor probe (Figure 6, (1)) for Note: Yanmar supplies a water separating damage if equipped. Inspect the bowl pre-filter separate from the engine. Location seal (Figure 6, (2)).
  • Page 59 25 N·m (18 ft-lb). negative (-) cable. 4. Start engine and check for water leaks. Checking or Replacing the Seawater Pump Impeller See your authorized Yanmar dealer or distributor. Replacing the Turbocharger Heat Shield See your authorized Yanmar dealer or distributor.

  • Page 60: Engine Mounts

    PERIODIC MAINTENANCE Checking Exhaust / Water Mixing Checking Hydraulic Oil Cooler Elbow See your authorized Yanmar dealer or See your authorized Yanmar dealer or distributor. distributor. Checking or Replacing Rubber Replacing Air Filter Element Hoses 1. Turn engine OFF. Check rubber water and fuel hoses for wear or damage.

  • Page 61: Every 500 Hours Of Operation

    Allow coolant to Checking the Fuel Pump and Fuel drain into a container of appropriate Lines size. See your authorized Yanmar dealer or distributor. ( 1 ) Draining and Refilling Closed Cooling System (Engine Coolant) 1. Disconnect battery negative (-) cable.

  • Page 62: Every 1000 Hours Of Operation

    Be sure the hose is securely Check flexible engine mounts for damage, connected and there is no damage. cracks or wear. See your authorized Yanmar 11. Fill the heat exchanger and recovery marine dealer or distributor for replacement. tank with approved coolant mix.See Adding Engine Coolant on page 32.

  • Page 63: Every 2000 Hours Of Operation

    2000 hours of operation or every 8 years, whichever comes first. • Replacing Seawater Pump Impeller • Replacing Alternator Belt Replacing Seawater Pump Impeller See your authorized Yanmar marine dealer or distributor for replacement. Replacing Alternator Belt See your authorized Yanmar marine dealer or distributor for replacement.
  • Page 64 PERIODIC MAINTENANCE This Page Intentionally Left Blank BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 65: Troubleshooting

    Problem / Symptom column in the Troubleshooting Chart to identify the If your engine does not operate properly, problem. refer to the troubleshooting chart or see your authorized Yanmar marine dealer or distributor. Provide the authorized Yanmar marine dealer or distributor with the following information: •...

  • Page 66: Troubleshooting Chart

    Action Engine Will Not Crank Discharged battery Charge / replace battery Blown fuse Replace fuse Defective starter motor See your authorized Yanmar dealer or distributor Loose wiring connections Tighten connections Electrical panel power circuit Reset circuit breaker breaker is tripped...

  • Page 67: Exhaust Color

    Cause Action White Smoke Cold engine Allow engine to warm to operating temperature See your authorized Yanmar deal- er or distributor Incorrect fuel Replace fuel with correct type Defective (leaking) fuel injector See your authorized Yanmar deal- er or distributor...

  • Page 68: Vibration - Drive Engaged

    Vibration - Drive Engaged Problem / Symptom Cause Action Rough at All Speeds Engine and propeller shaft mis- See your authorized Yanmar deal- aligned er or distributor Leaking cylinder head gasket Bent propeller shaft Rough at Higher Speeds Bent propeller...

  • Page 69: Engine Overheat

    Low coolant level Fill with coolant / inspect for leaks Clogged seawater filter (if equip- Clean ped) Clogged hydraulic cooler See your authorized Yanmar dealer or distributor Seawater pump worn or dam- aged Defective sensor / instrument Defective thermostat Damaged closed coolant pump...

  • Page 70: Diagnostic Trouble Codes

    The For further information, please contact your technician then can use a list to more quickly authorized Yanmar distributor or dealer. find the cause of the fault and correct it. BY Series Operation Manual...

  • Page 71: Diagnostic Trouble Code Table

    Code Charge Air Temp Over 110°C (230°F) reduce Code Boost Pressure 4BY2 - over 1.9 bar (27.5 psi) reduce alarm Code Reading (relative*) or 2.9 bar (42.0 psi) (absolute**) 6BY2 - over 2.3 bar (33.3 psi) (relative*) or 3.3 bar (42.9 psi)
  • Page 72 (ambient air pressure sensor) fail P0237 Boost Pressure Under 0.5 bar (7.3 psi) (abso- reduce alarm lute ** ) Boost Pressure Sen- No connection / short circuit to reduce alarm Ground BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 73 Not connected, short circuit alarm Spark No. 2 P0673 Glow System - Glow Not connected, short circuit alarm Spark No. 3 P0674 Glow System - Glow Not connected, short circuit alarm Spark No. 4 BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 74 P0690 Main Relay Power relay sense short circuit alarm high P2049 4BY2 - Injector Bank 1 Short circuit on high side to alarm Ground / B+ 6BY2 - Injector Bank 1 Short circuit on high side to reduce Ground / B+...

  • Page 75: Long-Term Storage

    Antifreeze from rusting. It is recommended that you see must be used to avoid freezing and your authorized Yanmar marine dealer or damaging of components. Antifreeze will distributor to prepare the engine for long- prevent rusting during long-term storage.

  • Page 76: Draining The Seawater Cooling System

    CAUTION! If seawater is left inside of the 3. Remove the seawater pump cover. See engine, it may freeze and damage parts your authorized Yanmar dealer or of the cooling system when the ambient distributor. temperature is below 0°C (32°F).

  • Page 77: Specifications

    Starter 12 V / 2 kW (2.7 hp) Charging System 12 V / 150 A Battery Capacity - Recom- 12 V / 85 Ah / 680 CCA (cold cranking amps) mended BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 78 Marine Gear (front-to- 644 mm (25.4 in.) 827.5 mm (32.6in.) marine gear mounting face) Overall Length 839.2 mm (33.0 in.) 1001 mm (39.4 in.) Width 670 mm (26.4 in.) (local exceeding) BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 79 **** The “Total Engine Lubricating Oil Capacity” includes oil in the oil pan, channels, coolers, and filter. The “Effective Engine Lubricating Capacity” indicates the difference in maximum scale of the dipstick and minimum scale. ***** Capacity may vary depending on installation angle. BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 80 SPECIFICATIONS This Page Intentionally Left Blank BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 81: Epa Warranty Usa Only

    THE ENGINES CERTIFIED TO UNITED Where a warrantable emissions condition STATES EPA 40 CFR 94 AND SOLD BY exists, Yanmar will repair your engine at no YANMAR THAT ARE INSTALLED IN charge to you for diagnosis, parts, and labor. VESSELS FLAGGED OR REGISTERED IN Warranty service or repair will be provided THE UNITED STATES.

  • Page 82: Warranty Period

    You must delivered by Yanmar to the original retail present your marine engine to an authorized purchaser. Such components may include Yanmar dealer or distributor as soon as a the following: problem exists. 1. Fuel Injection System 2.

  • Page 83: Customer Assistance

    Adairsville, GA 30103 warranty rights and responsibilities or would USA Telephone: 770-877-9894 like information on the nearest authorized Fax: 770-877-7567 Yanmar dealer or distributor, you should contact Yanmar Marine USA Corporation for assistance. BY Series Operation Manual © 2008 Yanmar Marine International...

  • Page 84: By Series Operation Manual

    EPA WARRANTY USA ONLY Maintenance Log Date Operating Maintenance Performed Dealer Name Stamp or Signa- Hours ture BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 85 EPA WARRANTY USA ONLY Date Operating Maintenance Performed Dealer Name Stamp or Signa- Hours ture BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 86 EPA WARRANTY USA ONLY BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 87 EPA WARRANTY USA ONLY BY Series Operation Manual © 2008 Yanmar Marine International...
  • Page 88 EPA WARRANTY USA ONLY This Page Intentionally Left Blank BY Series Operation Manual © 2008 Yanmar Marine International...

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